Flexible exothermic mat and method of use

ABSTRACT

An exothermic charge is secured to a flexible backing material forming an elongated mat. Grooves in the mat extending from the surface of the charge to the backing material allow the mat to be placed over a regular shape such as a pipe to provide a covering blanket of exothermic charge. The flexible mat is particularly useful in combination with insulation and other accessories for exothermically annealing welded pipe and the like in the field.

United States Patent n91 Bishop et al.

1 Aug. 7, 1973 1 FLEXIBLE EXQTHERMIC MAT AND METHOD OF USE [75] Inventors; Harold F. Bishop; James R. Deck,

both of Conneaut, Ohio {73] Assignee: Exomet, Incorporated, Conneaut,

Ohio

[22] Filed: July 19, 1971 [21] Appl. No.: 163,722

[52] [5.8. CI 148/127, 29/4985, 148/27, 149/2, 149/37 {51] Int. Cl B23k 23/00, C21d 9/08 [58] Field of Search 148/27, 127; 29/4935; 149/2, 37

[56] References Cited UNITED STATES PATENTS 3,163,113 12/1964 Davis et al. 149/37 X 3,192,080 6/1965 Cooper 148/127 3,307,997 3/1967 Detrick 149/2 X FOREIGN PATENTS OR APPLICATIONS 655,234 1/1963 Canada 148/127 661,422 4/1963 Canada H 148/127 936,972 9/1963 Great Britain 29/4985 Primary Examiner-Charles N. Lovell Att0rne vRonald B. Sherer et al.

[57] ABSTRACT An exothermic charge is secured to a flexible hacking material forming an elongated mat. Grooves in the mat extending from the surface of the charge to the hacking material allow the mat to be placed over a regular shape such as a pipe to provide a covering blanket of exothermic charge. The flexible mat is particularly uscful in combination with insulation and other accessories for exothermically annealing welded pipe and the like in the field.

5 Claims, 4 Drawing Figures PMENTED AUG 7 SHEEI 1 [If 2 59/ Hora/d E Bishop y James R. Deck Pmmmw Hm 3.751.308

SHEEI 2 OF 2 IN VENTORS 2 Harold E Bishop y James R. Dec/r CW ATTORNEY FLEXIBLE EXOTI-IERMIC MAT AND METHOD OF USE BACKGROUND OF THE INVENTION This invention pertains to heat treating of welded joints in structural elements by means of exothermic charges placed around the area to be treated. In the construction industry and in particular in construction of process plants employing many miles of pipe; the pipe is installed by welding successive lengths and joints such as tees, elbows, reducers, and the like at the construction site. Because the pipe sections are welded together, the welds and heat affected zones must be given a post-welding thermal treatment in order to reduce the residual stresses inher-ent in a weld where there was non-controlled cooling of the weldment. The type of post heat treatment depends upon the overall size, composition, and wall thickness of the welded sections and can be at a temperature either above or below the critical temperature As a general rule the weld is heated to below the critical temperature for the metal composition, allowed to achieve temperature uniformity throughout the section being heated and then the temperature is gradually reduced to ambient. To a large extent the post-welding heat treatment, i.e., time, temperature and rate of cooling, are specified by industry and local building codes.

The most successful method of post-welding heat treatment of pipe and the like erected in the field is by an apparatus and method developed by Exomet, Inc. of Conneaut, Ohio, and marketed under the name EXO- ANNEAL. The EXO-ANNEAL apparatus consists of a kit containing shaped exothermic charges, insulation both high temperature and low temperature, insulating cement, sealing rings and fastening wires. Each kit is made up at the factory for a pre-ordered pipe size and can only be used on that size. The insulation and other components are selected and packed accordingly. In a large installation this requires a large number of kits to be in inventory to accommodate the varying pipe grades and sizes.

U. S. Pat. No. 3,l92,080, is drawn to an exothermic heat treating apparatus and method also employing pre-shaped parts. This method has never been adopted because of the use of different exothermic sleeves in each unit or kit.

BRIEF DESCRIPTION OF THE INVENTION In order to avoid the above-mentioned problems with prior art exothermic heat treating devices and to provide an improved method and apparatus for exothermically treating weldments, it has been discovered that when the exothermic charge is affixed to a flexible backing or reenforcing in the form of a blanket or mat in a manner that allows shaping of the mat to regular surfaces in the field, and the mat combined with proper insulation can be used for many different sizes and grades of pipe and to provide a broad range of thermal treatments. The mat of exothermic material can be readily cut to the length and width desired in the field and shaped by hand because of apertures or grooves molded into the mat by the manufacturer. With this mat there is no need for large inventories of kits as the mat can be used at elbows, tees and the like.

Therefore, it is the primary object of this invention to provide a method and apparatus for post heat treatment of weldments.

It is another object of this invention to provide a flex ible exothermic charge in the form of a mat.

It is still another object of this invention to provide a method for using a flexible exothermic charge in combination with insulation and fastening devices in order to accomplish controlled thermal treatment of a weldment.

BRIEF DESCRIPTION OF THE DRAWING FIG. I is an enlarged fragmented front view of the exothermic mat according to the present invention.

FIG. 2 is a plan view of the exothermic mat with portions broken away to illustrate a method of application to a flexible backing.

FIG. 3 is an isometric view of a pipe to elbow joint ready for exothermic heat treating according to the present invention, certain portions of the installation having been eliminated for the sake of clarity.

FIG. 4 is a section taken along lines 44 of FIG. 3 with the removed portions shown for clarity.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Referring to the drawing and in particular to FIGS. 1 and 2, there is shown a molded exothermic mat 10 of a composition within the following broad range:

Constituent Percent by Weight Fuel 15-30 Binder 340 Oxidizers 15-35 Flux 0.5-3.0 Refractory 25-40 In the above compositions the preferred fuel is finely divided aluminum in the form of 200 mesh (Tyler Standard Sieve Series) powder, grindings of mesh and chopped foil in the range of 20 to +200 mesh; the binder is starch, phenolic resin, natural sugars, synthetic sugars or mixtures thereof; the oxidizers are selected from the group consisting of manganese dioxide, red iron oxide (Fe,O,-,), barium nitrate, sodium nitrate and mixtures thereof; the flux is cryolite; and the preferred refractory is ground fire brick in the size range of 20 to mesh.

A preferred exothermic composition is:

Constituent by weight Al Foil 19.4 Phenolic Resin 8.6 Red Iron Oxide 34.0 Cryolite 1.7 Ground Fire Brick 36.3

In the above formula the aluminum foil and ground fire brick were found to have a particle size distribution as follows:

Tyler Sieve Size Percent Retained (mesh) Al Foil Brick 20 0 4 35 60 59 50 20 20 100 l6 I6 50 2 Pan 2 l The exothermic mat 10 is formed around a flexible backing 12 such as a wire screen with openings of approximately one inch. The mat 10 has a series of generally parallel and equally spaced grooves 14 disposed perpendicular to one edge of the mat 10. It is preferable that the mat 10 has a generally rectangular shape in top view so the grooves I4 are perpendicular to the long side of the rectangle. Grooves 14 extend from the top surface 18 to the flexible backing l2 and have a generally "V"-shaped cross section. A second series of grooves 16 (FIG. 2) are provided perpendicular to grooves 14. These second grooves 16 are generally parallel to each other and equally spaced across the mat, extending in depth to a point above the flexible back 12.

The purpose of grooves I4 is to allow the mat 12 to be wrapped around a regular surface such as a pipe with the result that the pipe is uniformly surrounded by an exothermic mat or blanket. This is illustrated in FIG. 3 and will be more fully described hereinafter.

Grooves 16 are provided so that the mat 10 can be cut to varying widths for a given length.

Manufacture of the mat 10 is carried out using a molding box provided with projections in the bottom corresponding to the required grooves 14 and 16. After the box is filled with the exothermic mix, a wire screen I2 or other backing is embedded therein. It may be desirable to put additional notches (not shown) in the blanket on the surface 20, opposite to the notch 14, openings on surface 18, to aid in field installation of the blanket. After baking, the blanket is hard and relatively brittle so that it can be handled and when required formed to shape.

Mats according to the present invention are particularly used for pipe sizes of four inches outside diameter and larger. To accommodate this range of pipe sizes, mats are made according to the following dimensions:

Overall Length 30 inches Overall Width l2 inches Overall Thickness K inches Distance Between Grooves 14 is inches Width of Grooves 14 Is inches Depth of Grooves l4 '6 inches Distance Center line of Grooves l6 2 inches Shape of Grooves I4, 16 "V The above dimensions are critical to the extent they have proven satisfactory for uses as will hereinafter be described. The dimensions of grooves 16 are not necessarily described because these grooves serve only as the means for determining the width of blanket to be used.

Referring now to FIGS. 3 and 4, there is shown a pipe 22 to elbow 24 connection by weld seam 26. In order to relieve the stresses in the weld and surrounding base metal, exothermic mats 10', 10'', together with neces sary accessories, will be installed on the joint.

The first step is installation of a layer of thin flexible insulation 28 around the pipe 22 and elbow 26 where the exothermic is to be placed. The insulation must overlap the weld according to the temperature desired as is specified for the pipe size and composition. Next two layers of exothermic mat l and are placed over the insulation 28. The width of the mat is selected according to the temperature and in the case of a pipe to elbow, the thinner rings are added to assure uniform heating of the entire heat affected area of the joint. After the exothermic mats 10', 10" are in place they are covered with a 2-inch strip of heavier insulation 30, over which is placed a final support wire 32. The insulation 30 is spaced about 4 inches apart on full width mats and the wires 32 assure in situ reaction of the exothermic composition. The voids between the mats are filled with a low temperature insulation 34, and the entire assembly is covered with a composite outer insulation 36 and secured in place with wires 38 (FIG. 3). Additional low temperature insulation 40, 42 (FIG. 4) is placed at the outer ends of the exothermic and fas tened with wires (not shown). Insulation 40, 42 is mounted so that it can be moved away from the insula tion in order to ignite the mats I0, 10''. After reaction of the mats I0, 10'', the insulation 40, 42 can be moved against the mats in order to control the cooling of the entire assembly.

Set forth in Examples 1-4 are required items and sizes in order to accomplish exothermic post-welding heat treatment according to the present invention.

EXAMPLE I 4" Schedule 40 or Standard Weight Pipe to Pipe Joint Stress Relieved at I150 to I275F Item No. of Pieces Width Length Insulation 28 (0.062" thick) 6" 29%" Exothermic Mat 10' I 6" I856" Exothermic Mat 10" I 6" 23%" Insulating Strips 30 2 2" 29" Insulation 36 l 7" 36" Insulation 42 2 l6" 2 I EXAMPLE ll 4" Schedule 80 or extra heavy Pipe to Pipe Joint Stress Relieved at 1350' to 1475F Item No. of Pieces Width Length Insulation 28 (0.062" thick) I I4" 29%" Exothermic Mat 10' I I4 18%" Exothennic Mat 10" I I4" 23%" Insulating Strips 30 4 2" 29" Insulation 36 I I5" 36" Insulation 72 2 l6 2 I EXAMPLE III l0" Schedule 20 Pipe to Pipe .Ioint Anneal at l550 to I650F Item No. of Pieces Width Length Insulation 28 (0.062" thick) I I8" 34" Exotherrnic Mat [0 I I8" 36%" Exotherrnic Mat I0" I I8" 42%" Exothermic Mat I I8" 48%" Insulating Strips 30 5 2" 55" Insulation 36 1 I9" Insulation 42 2 l6" 4t" Sealing Insulation 2 4" 53" Third mat placed over mat I0" in same manner as described. Placed at the joint of insulation 36 and 42 covering insulation 42.

EXAMPLE IV 20" Schedule 30 pipe to pipe joint Il50 to I275F stress relieve treatment Item No. of Pieces Width Length Insulation 2! (0.023" thick) I 24" 63" Exothermic Mat 10' I 24" 65 94" Exothennic Mat 10" I 24" 7I" Insulating Strips 30 8 2" Insulation 36 I I5" 94" Insulation 2 2 I6" 70" In the above examples, insulation 28 is an asbestos paper having an asbestos fiber content of 99 percent and is sold by JohnsManville as asbestos welding paper. The insulating strips 30 are l4 inch thick and are prepared, commercially available, white insulating asbestos. They serve to prevent burn through of wires 32 during reaction of the exothermic charge. In place of wire 32 regular commercial metal banding or strapping can be used. Insulation 36 is a composite consisting of asbestos welding paper next to the exothermic mat; to this is fastened an alumina-silica fiberous insulation about 5% inch thick having a density of eight pounds per cubic foot and is sold under the tradename CERA- FELT by Johns-Manville; this is covered by a layer of mineral fiber blanket 2" thick having a density of eight pounds per cubic foot, sold by Eagle-Picher Industries, Inc. under the tradename SUPERGLAS. The insulation 42 and sealing insulation of Example Ill are made from the same mineral fiber as the outer 2 inches of insulation 36.

From the above examples it can be seen that the apparatus and method of the instant invention is applicable to an infinite variety of exothermic heat treating problems, The method can be tailored to fit the pipe size, shape, composition, joint and atmospheric conditions to satisfy all weld treating codes. In the matter of insulation this can be varied to accomplish longer or shorter post heating cooldown depending upon the material.

Flexible exothermic mats and accessories according to the present invention can also be used to pre-heat pipe sections prior to welding as well as for other routine maintenance work in the field.

The exothermic can be manufactured on a plastic, paper, cardboard, thin foil, carpet or other flexible backing that may or may not be within the exothermic. Once the exothermic is in place, the backing has really served its purpose. The primary purpose of the perforated back is to provide structural strength to the exothermic mat and to allow cutting of the mat to the proper length and width without unnecessary crumbling of the exothermic.

Having thus described our invention, the following is desired to be secured by Letters Patent of the United States.

We claim:

1. A method of thermally treating a welded pipe joint by heating the weld joint to a temperature of between 50F to 1650F for a time sufficient to bring the weld and the immediately adjacent area to the desired temperature and thereafter cooling said joint to ambient temperature comprising the steps of:

placing a relatively thin layer of a first insulating material around that portion of the pipes and joint to be contacted by an exothermic charge;

surrounding the joint and first insulation layer with a formable exothermic material, said exothermic material comprising a flexible backing; disposed around the backing is an exothermic charge, said charge consisting essentially of to 30 percent by weight of a fuel selected from the group consisting of 200 mesh aluminum powder, mesh alumi num grindings, -20 to +200 chopped aluminum foil and mixtures thereof; 3 to 10 percent by weight of a binder selected from the group consisting of starch, phenolic resin, natural sugars, synthetic sugars and mixtures thereof, 15 to 35 percent by weight oxidizers from the group consisting of manganese dioxide, red iron oxide, barium nitrate, sodium nitrate and mixtures thereof, 0.5 to 3.0 percent by weight of a flux, balance refractory of a particle size of 20 to +l50 mesh, said charge having a series of grooves generally parallel to the axis of the pipes and uniformly spaced one from the other, said grooves extending from the surface of the charge opposite the pipe to the backing material;

covering the major portion, the exothermic, with a second layer of insulation;

igniting the exothermic and allowing the exothermic charge to react completely;

covering the entire exothermic after burning; and allowing the covered exothermic assembly to remain in place until the joint reaches ambient temperature.

2. A method according to claim 1 wherein auxiliary low-temperature insulation is placed around the exposed pipe for a predetermined distance on either side of the formable exothermic and is affixed to said joint in contact with the exposed edges of said formable exo thermic.

3. A method according to claim 1 wherein additional formable exothermic is shaped into relatively thin rings for treating welds at other than straight line joints, such as pipe to elbow, pipe to tee, and the like and said rings are placed at a location away from the primary exothermic material with at least one point of each ring contacting its neighboring ring and the ring adjacent the primary exothermic material making at least a point contact therewith.

4. A method according to claim 3 wherein insulation is placed in the spaces between the exothermic rings and the exothermic material.

5. A method according to claim 4 wherein the entire ring and primary exothermic material assembly is covered with a layer of insulation.

* l i t 

2. A method according to claim 1 wherein auxiliary low-temperature insulation is placed around the exposed pipe for a predetermined distance on either side of the formable exothermic and is affixed to said joint in contact with the exposed edges of said formable exothermic.
 3. A method according to claim 1 wherein additional formable exothermic is shaped into relatively thin rings for treating welds at other than straight line joints, such as pipe to elbow, pipe to tee, and the like and said rings are placed at a location away from the primary exothermic material with at least one point of each ring contacting its neighboring ring and the ring adjacent the primary exothermic material making at least a point contact therewith.
 4. A method according to claim 3 wherein insulation is placed in the spaces between the exothermic rings and the exothermic material.
 5. A method according to claim 4 wherein the entire ring and primary exothermic material assembly is covered with a layer of insulation. 